Figgered it out! Coincident with the previous changes I had replaced the screws with new and longer ones. Some of the nutplate sites were not drilled through the inner skin, and the end of the screws were hitting this, and pushing up the outer skin and deforming the door! I drilled out the inner skin and cleaned up, and all nutplate sites sit perfectly flat. What an a$$hole!
Retaped the door and refitted the center nutplate with flox.
Finish sanded the main landing gear leg tops, 320g wet. Had to pop the wheels off to get at the tricky bits.
